Face shield for rigid protective headwear

ABSTRACT

A thermoformed protective face shield includes a curved top portion adapted to conform to a curved lower portion of a rigid protective headwear. The face shield further includes a visor portion extending outward from a lower end of the curved top portion, thereby creating a space between the user&#39;s face and a face cover portion. The visor portion includes one or more channels formed therein for structural support and/or allowing release of heat and/or moisture from the face cover portion. The face cover portion extends downward from the visor portion and covers and provides protection for the face of a user. A side shield portion extends inwardly from the face cover portion. For shielding the sides of a user&#39;s face. Further, a perimeter flange may extend perpendicular to the perimeter of the face shield for providing structural support to the face shield.

FIELD

The embodiments of the invention are generally related to face masks or shields for use with rigid protective headwear.

BRIEF SUMMARY

A thermoformed protective face shield includes a curved top portion adapted to conform to the forehead portion of a rigid protective headwear. The face shield further includes a visor portion extending outward from a lower end of the curved top portion, thereby creating a space between the user's face and a face cover portion. The face cover portion extends downward from the visor portion and covers and provides protection for the face of a user. A side shield portion may extend inward from the face cover portion for shielding the sides of a user's face. A perimeter flange may extend perpendicular to the perimeter of the face shield for providing structural support to the face shield and additional protection to the user. The visor portion may include one or more channels to provide structural support and/or ventilation.

The above discussed and other features and advantages of the present face shield will be appreciated and understood by those of ordinary skill in the art from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like elements are numbered alike in the several Figures:

FIG. 1 is a front view of the present face shield;

FIG. 2 is a left side view of the face shield illustrated in FIG. 1;

FIG. 3 is a top view of the face shield illustrated in FIG. 1;

FIG. 4 is a bottom view of the face shield illustrated in FIG. 1;

FIG. 5 is a right side view of the face shield illustrated in FIG. 1;

FIG. 6 is a back view of the lace shield illustrated in FIG. 1;

FIG. 7 is a perspective left side view of the face shield illustrated in FIG. 1;

FIG. 8 is a perspective right side view of the face shield illustrated in FIG. 1;

FIG. 9 is a front view of the present face shield worn by a user wearing rigid protective headwear;

FIG. 10 is a right side view of the present face shield worn by a user wearing rigid protective headwear;

FIG. 11 is a back view of the present face shield worn by a user wearing rigid protective headwear;

FIG. 12 is a top view of the present face shield worn by a user wearing rigid protective headwear;

FIG. 13 is a side view of the present face shield worn by a user wearing rigid protective headwear as illustrated in FIG. 12, taken along line A-A; and,

FIG. 14 is a representative illustration of a rigid protective headwear.

DETAILED DESCRIPTION

The face shield of the disclosed embodiments is illustrated in FIGS. 1-13. With reference to FIG. 1, face shield 10 generally includes a curved top portion 15, a visor portion 50, a face cover portion 60, a side shield portion 70, and a perimeter flange 80.

With reference to FIGS. 1 and 2, curved top portion 15 is shaped to substantially conform to the forehead portion of a rigid protective headgear, and includes an upper end and a lower end. Visor portion 50 extends outwardly from the lower end of curved top portion 15 and may include one or more channels, as indicated at 20.

Any one or all of channels 20 may be solid or have sealed ends, thereby serving to provide structural support to visor portion 50. Alternatively any one or more channels 20 may include an airway which, as shown in FIG. 3, may include an intake end 22 in air communication with face cover portion 60 and a discharge end 24 in air communication with the ambient atmosphere, thereby allowing heat and/or moisture to move from behind face cover portion 60 through channel 20 and into the ambient atmosphere. This helps to prevent face shield 10 and/or a user's glasses, if applicable, from fogging, and increases user comfort by curtailing heat and/or moisture buildup inside face shield 10. The number of channels shown in the figures is not limiting, and a larger or smaller number of channels may be used, which moreover may vary in shape and/or size from those illustrated without departing from the present scope.

As noted above, face shield 10 includes visor portion 50 extending outwardly from the lower end of curved top portion 15. As shown for example in FIGS. 10, 13, and 14, visor portion 50 may be formed to substantially conform to a brim portion 11.5 of rigid protective headgear 100 with which face shield 10 is used. Visor portion 50 in combination with brim portion 115 provides a space between a user's face and face cover portion 60, as shown for example in FIGS. 10 and 13. Face cover portion 60 extends downward from visor portion 50 over a user's eyes, nose, and mouth.

At least one of face cover portion 60, visor portion 50, and side shield portion 70 may be formed from an optically dear material. In one embodiment, each of face cover portion 60, visor portion 50, and side shield portion 70 are formed from an optically dear material, thereby allowing a user to clearly see through face shield 10 at all angles. In yet another embodiment, any one or all of face cover portion 60, visor portion 50, and side shield portion 70 may be formed from and/or layered with a photochromic material to provide an adaptive response to ambient lighting conditions.

As previously discussed, heat and moisture can build up in the space between a user's face and face cover portion 60, causing fogging of face cover portion 60 and/or of a user's glasses, if applicable. An airway may be provided in channel(s) 20 to provide an exhaust mechanism for such heat and/or moisture to move out of face cover portion 60, such as by convection and/or in response to the user's breathing. In particular, heat and moisture that could potentially build up behind face cover portion 60 enters the intake end(s) 22 of the channel(s) 20 and exits the discharge end(s) 24 of the channel(s) 20. Thus, the buildup of heat and moisture, and any resulting fogging, is reduced or prevented.

Side shield portion 70 is made up of a plurality of side segments extending rearwardly from face cover portion 60. In the embodiment shown in HG. 1, side shield portion 70 is made up of seven side segments; however, a larger or smaller number of side segments may be used. The side segments are relatively planar segments that come together at angles to provide a shield that surrounds the sides and bottom of a user's face. As shown for example in FIGS. 1 and 2, intermediate side segments 75 may also be included between the side segments and the face cover portion 60, such as to provide a more conformed and thorough fit.

Face shield 10 may include a perimeter flange 80 extending approximately perpendicularly from the perimeter of the face shield 10. As shown in FIG. 1, perimeter flange 80 extends from the curved top portion 15 and side shield portion 70 such that the perimeter flange 80 is present around the perimeter of face shield 10. Perimeter flange 80 provides structural support and integrity to face shield 10 regardless of the starting thickness of the material used to mold face shield 10.

FIG. 4 shows face shield 10 looking up from the bottom, with perimeter flange 80, side shield portion 70, intermediate side segments 75.

FIG. 5 is a view of face shield 10 from the right side of a user, showing curved top portion 15. Visor portion 50 extends outwardly from the lower end of curved top portion 15 and includes channel 20. Face cover portion 60 extends downward from visor portion 50, with side shield portion 70 and intermediate side segments 75 providing additional coverage of the user's face, Perimeter flange 80 extends from curved top portion 15 and side shield portion 70 and is present around the perimeter of face shield 10.

FIG. 6 is a view from the back of face shield 10, looking forward. Again, the lower end of curved top portion 15 meets visor portion 50, which bears one or more channels 20. Any one or more of channels 20 may include an airway with an intake end 22 and a discharge end 24, Intake end 22 is in air communication with the interior volume formed by face cover portion 60 and side shield portion 70 and, if present, intermediate side segments 75, and the face of a user. Heated and/or moist air in this interior volume may enter intake end 22 and exit discharge end 24 of channel 20, reducing the presence of heat and/or moisture adjacent the face of the user.

FIG. 7 is a front perspective view of face shield 10 from the upper left side. The lower end of curved top portion 15 transitions into visor portion 50 which, as shown in this particular embodiment, bears four channels 20. Any one or more of channels 20 may be solid or have sealed ends, and serve to provide rigidity to visor portion 50 and/or to strengthen the connection between curved top portion 15 and face cover portion 60. Alternatively, any one or more of channels 20 may include an intake end 22, a discharge end 24, and an airway connecting them to allow heat and/or moisture to move from the interior of face cover portion 60 to the ambient atmosphere. Face cover portion 60, side shield portion 70, and intermediate side segments 75 cover the front and sides of a user's face, while perimeter flange 80 provides structural support around the perimeter of face mask 10.

FIG. 8 is a front perspective view of face shield 10 from the lower right side, and shows in particular the relationship among face cover portion 60, side shield portion 70, and intermediate side segments 75 in substantially surrounding the face of a user.

FIG. 9 is a front view looking at a user wearing face shield 10 with rigid protective headwear 100. Curved upper portion 15 is positioned over curved lower portion 110 (not shown) of rigid protective headwear 100, and visor portion 50 is positioned over brim portion 115 (also not shown) of rigid protective headwear 100. Face cover portion 60, side shield portion 70, and intermediate side segments 75 substantially surround the face of a user and, with that face, form an interior volume which may become warm and/or humid during use. Channel(s) 20 may include an intake end 22 and discharge end 24 connected by an airway to allow heat and/or moisture to move out of that volume and into the ambient atmosphere.

FIG. 11 is a rear view looking at the back of the head of a user wearing rigid protective headwear 100 and face shield 10, showing in particular side shield portion 70 and intermediate side segments 75 with perimeter flange 80.

FIG. 12 provides a view looking down on a user wearing face shield 10 and rigid protective headwear 100. From this perspective one can see curved top portion 15; and, visor portion 50 extending outwardly (to the left, from this perspective) from the lower end of curved top portion 15, with channels 20 having intake ends 22 and discharge ends 24.

Face shield 10 may be formed as a one-piece unit from a thermoplastic material. As previously indicated, this material may be a transparent, optical grade thermoplastic material; or may be, incorporate, or be layered with a material that prevents certain wavelengths of the electromagnetic spectrum, or certain amounts of certain wavelengths, from passing through, The process for forming face shield 10 includes heating a plastic sheet before bringing it over a mold cavity and utilizing vacuum to form the sheet to the mold cavity. After removing the formed part from the mold cavity, the perimeter of the formed part is trimmed from a web of the sheet using a die. In addition, face shield 10 may be customized to fit a particular user by trimming, as with scissors. Alternatively, one or more portions of face shield 10 may be formed as separate pieces and then joined by any suitable means, including ultrasonic welding or gluing.

Any suitable thickness of material may be used to mold face shield 10. In one embodiment, the material may be from about 0.025 inches thick to about 0.156 inches thick. Typically, a medical grade polyethylene terephthalate glycol is used. However, other suitable materials include polyvinyl chloride, polycarbonate, or polyethylene terephthalate. The material is light-weight to provide a lightweight comfortable face shield that may be comfortably worn for prolonged periods of time.

Face shield 10 may be attached or releasably connected to protective rigid headwear 100 in any suitable manner. For example, tape, including single-sided tape, may be used to connect curved top portion 15 and/or visor portion 50 to protective rigid headwear 100. Such tape may run from the outer surface of face shield 10, such as the outer surface of curved top portion 15, to the outer surface of curved upper portion 105 of protective rigid headwear 100 that extends beyond curved top portion 15 when face shield 10 is engaged with rigid protective headwear 100.

Alternatively or in addition, double-sided tape may be placed on the inner surface of curved top portion 15 and/or of visor portion 50, and/or on the corresponding outer surface of curved lower portion 110 and/or brim portion 115, and the corresponding surfaces of face shield 10 and rigid protective headwear 100 may then be brought into contact, whereby the tape will adhere face shield 10 to protective rigid headwear 100. On the present context, “inner” refers to the side facing the user, which may also be thought of as the interior side, while “outer” refers to the side facing away from the user, which may also be thought of as the exterior side.)

In another embodiment, a hook-and-loop fastener or fasteners may be used. For example, either the hook portion or the loop portion of a hook-and-loop fastener may be adhered to the inner surface of curved top portion 15 and/or of visor portion 50; the corresponding loop portion or hook portion of the hook-and-loop fastener may be adhered to, respectively, the outer surface of curved lower portion 110 or the outer surface of brim portion 115; and the corresponding surfaces of face shield 10 and rigid protective headwear 100 may then be brought into contact to engage the hook-and-loop fastener.

In yet another embodiment, one or more snap fasteners may be used, with the male half or the female half of the snap fastener being glued, riveted, or otherwise attached to the inner surface of curved top portion 15 and/or of visor portion 50; the corresponding female half or male half of the snap fastener may be glued, riveted, or otherwise attached to, respectively, the outer surface of curved lower portion 110 and/or the outer surface of brim portion 115; and the corresponding surfaces of face shield 10 and rigid protective headwear 100 may then be brought into contact to enable snapping the male half and the female half together.

Additional embodiments for connecting the present face shield to rigid protective headwear may be readily envisioned, including but not limited to using an elastic or tensionable band positioned substantially horizontally around the outer circumference of rigid protective headwear 100 and passing over the outer surface of curved top portion 15. A relatively permanent form of connection between face shield 10 and rigid protective headwear 100 may also be used, such as adhesive. Other forms of connection will be readily apparent and may be employed without departing from the present scope.

While some exemplary embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. 

What I/we claim is:
 1. A thermoformed protective face shield comprising: a) a curved top portion adapted to conform to a curved lower portion of a rigid protective headwear; b) a visor portion extending outwardly from a lower end of said curved top portion and adapted to conform to a brim portion of the rigid protective headwear, said visor portion including a plurality of channels each having a first end and a second end; c) a face cover portion extending downward from said visor portion for shielding the face of a user of the rigid protective headwear; d) a side shield portion extending inwardly from the face cover portion for shielding the sides of a user's face; and e) a perimeter flange extending substantially perpendicular to the perimeter of the face shield for providing structural support to the face shield.
 2. The thermoformed protective face shield of claim 1, further wherein at least one of said plurality of channels comprises an airway having an intake end and a discharge end for allowing movement of moisture and/or heat away from said face cover portion.
 3. The thermoformed protective face shield of claim 2, further wherein each of said plurality of channels comprises an airway having an intake end and a discharge end for allowing movement of moisture and/or heat away from said face cover portion.
 4. The thermoformed protective face shield of claim 1, wherein said face cover portion is substantially planar.
 5. The thermoformed protective face shield of claim 1, wherein said side shield portion comprises a plurality of side segments extending rearwardly from said face cover portion.
 6. The thermoformed protective face shield of claim 5, wherein said plurality of side segments are relatively planar and come together at an angle to provide a shield that substantially surrounds the sides and bottom of a user's face.
 7. The thermoformed protective face shield of claim 5, further comprising intermediate side segments positioned between said side shield portion and said face cover portion.
 8. The thermoformed protective face shield of claim 1, wherein said perimeter flange is present around the perimeter of said thermoformed protective face shield.
 9. The thermoformed protective face shield of claim 1, wherein at least one of said visor portion, said face cover portion, and said side shield portion are formed from an optically clear material.
 10. The thermoformed protective face shield of claim 9, further wherein at least one of said visor portion, said face cover portion, and said side shield portion is comprised of or layered with a blocking material that at least partially blocks one or more portions of the electromagnetic spectrum.
 11. The thermoformed protective face shield of claim 10, wherein said blocking material is a photochromic material.
 12. The thermoformed protective face shield of claim 9, wherein said optically clear material is polyethylene terephthalate glycol, polyvinyl chloride, polycarbonate, or polyethylene terephthalate.
 13. The thermoformed protective face shield of claim 1, wherein the outer surface of at least one of said visor portion and said curved top portion comprises tape having a first portion and a second portion, wherein said first portion is attached to said outer surface and said second portion is configured for attachment to the rigid protective headwear.
 14. The thermoformed protective face shield of claim 1, wherein the inner surface of at least one of said visor portion and said curved top portion comprises at least one of: a. double-sided tape, b. the hook portion of a hook-and-loop fastener, c. the loop portion of a hook-and-loop fastener, d. the female half of a snap fastener, e. the male half of a snap fastener, and f. an adhesive. 